Metal High-K Transistor Having Silicon Sidewall For Reduced Parasitic Capacitance, And Process To Fabricate Same

ABSTRACT

A method is disclosed to reduce parasitic capacitance in a metal high dielectric constant (MHK) transistor. The method includes forming a MHK gate stack upon a substrate, the MHK gate stack having a bottom layer of high dielectric constant material, a middle layer of metal, and a top layer of one of amorphous silicon or polycrystalline silicon. The method further forms a depleted sidewall layer on sidewalls of the MHK gate stack so as to overlie the middle layer and the top layer, and not the bottom layer. The depleted sidewall layer is one of amorphous silicon or polycrystalline silicon. The method further forms an offset spacer layer over the depleted sidewall layer and over exposed surfaces of the bottom layer.

TECHNICAL FIELD

The exemplary embodiments of this invention relate generally tosemiconductor devices and methods to fabricate them and, morespecifically, exemplary embodiments of this invention relate to a classof devices known as metal high dielectric constant (high-k or MHK)transistors.

BACKGROUND

MHK transistors are experiencing extremely active development in theindustry. One observed problem relates to the presence of an elevatedouter fringe capacitance (Cof), on the order of 40-80 aF/μm. Theelevated value of Cof is of concern, in that it at least impairs highfrequency operation of the MHK transistor.

In U.S. Pat. No. 7,164,189 B2 Chien-Chao Huang et al. describe a methodthat includes providing a semiconductor substrate including apolysilicon or a metal gate structure including at least one overlyinghardmask layer; forming spacers selected from the group consisting ofoxide/nitride and oxide/nitride/oxide layers adjacent the polysilicon ormetal gate structure; removing the at least one overlying hardmask layerto expose the polysilicon or metal gate structure; carrying out an ionimplant process; carrying out at least one of a wet and dry etchingprocess to reduce the width of the spacers; and, forming at least onedielectric layer over the polysilicon or metal gate structure andspacers in one of tensile and compressive stress.

In U.S. Pat. No. 6,448,613 B1 Bin Yu describes a field effect transistorthat is fabricated to have a drain overlap and a source overlap tominimize series resistance between the gate and the drain and betweenthe gate and the source of the field effect transistor. The parasiticMiller capacitance formed by the drain overlap and the source overlap issaid to be reduced by forming a depletion region at the sidewalls of thegate structure of the field effect transistor. The depletion region isformed by counter-doping the sidewalls of the gate structure. Thesidewalls of the gate structure at the drain side and the source side ofthe field effect transistor are doped with a type of dopant that isopposite to the type of dopant within the gate structure. Such dopant atthe sidewalls of the gate structure forms a respective depletion regionfrom the sidewall into approximately the edge of the drain overlap andsource overlap that extends under the gate structure to reduce theparasitic Miller capacitance formed by the drain overlap and the sourceoverlap.

At least one drawback of this latter approach is that it does notaddress the reduction of parasitic Miller capacitance when metal-likematerials (such as TiN) are used.

SUMMARY

The foregoing and other problems are overcome, and other advantages arerealized, in accordance with the exemplary embodiments of thisinvention.

In a first aspect thereof the exemplary embodiments of this inventionprovide a method to form a metal high dielectric constant (MHK)transistor, where the method includes providing a MHK stack disposed ona substrate, the MHK stack comprising a layer of high dielectricconstant material and an overlying layer comprised of a metal, the MHKstack having an overlying layer comprised of silicon; selectivelyremoving only the layer comprised of silicon and the layer comprised ofmetal, without removing the layer of high dielectric constant material,to form an upstanding portion of a MHK gate structure comprised of aportion of the layer comprised of silicon, an underlying portion of thelayer comprised of metal, and an overlying portion of the layercomprised of silicon; forming a sidewall layer comprised of silicon onsidewalls of the upstanding portion of the MHK gate structure; removingthat portion of the layer of high dielectric constant material than doesnot underlie the upstanding portion of the MHK gate structure; andforming an offset spacer layer over the sidewall layer and over exposedsurfaces of a remaining portion of the layer of high dielectric constantmaterial that underlies the upstanding portion of the MHK gatestructure.

In a further aspect thereof the exemplary embodiments of this inventionprovide a MHK transistor that comprises a substrate; a MHK gatestructure disposed on the substrate between a source region and a drainregion, the MHK gate structure comprising a layer of high dielectricconstant material and an overlying layer comprised of a metal, the MHKgate structure having an overlying layer comprised of silicon, where alateral extent of the layer of high dielectric constant material isgreater than a lateral extent of the overlying layer of metal; asidewall layer comprised of silicon disposed on sidewalls of the MHKgate structure to cover the layer comprised of metal and the overlyinglayer comprised of silicon, said sidewall layer also being disposed overa top surface of the underlying layer of high dielectric constantmaterial; and an offset spacer layer disposed over the layer comprisedof silicon and over exposed portions of the layer of high dielectricconstant material.

In another aspect thereof the exemplary embodiments of this inventionprovide a method to reduce parasitic capacitance in a metal highdielectric constant (MHK) transistor. The method includes forming a MHKgate stack upon a substrate, the MHK gate stack comprising a bottomlayer comprised of high dielectric constant material, a middle layercomprised of metal, and a top layer comprised of one of amorphoussilicon or polycrystalline silicon; forming a depleted sidewall layer onsidewalls of the MHK gate stack so as to overlie the middle layer andthe top layer, and not the bottom layer, said depleted sidewall layercomprised of one of amorphous silicon or polycrystalline silicon; andforming an offset spacer layer over the depleted sidewall layer and overexposed surfaces of the bottom layer.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other aspects of the embodiments of this invention aremade more evident in the following Detailed Description, when read inconjunction with the attached Drawing Figures, wherein:

FIGS. 1A through 1G are each an enlarged cross-sectional view of asemiconductor-based structure and depict metal gate process flow inaccordance with the exemplary embodiments of this invention.

DETAILED DESCRIPTION

Although well-known to those skilled in the art, certain abbreviationsthat appear in the ensuing description and/or in the Figures are definedas follows:

BOX buried oxide CMOS complementary metal-oxide semiconductor CVDchemical vapor deposition FET field effect transistor HfO₂ hafnium oxideMLD multi-layer deposition PECVD plasma enhanced chemical vapordeposition PR photoresist RIE reactive ion etch RTA rapid thermal annealSOI silicon on insulator STI shallow trench isolation TiN titaniumnitride poly polycrystalline silicon Si silicon

The inventors have realized that, as compared to conventional poly-gatedFETs, the origin of the increased Cof is due to a lack of sidewalldepletion in the metal gate. This added capacitance adds to the Millercapacitance (Cmiller) and thus has a tangible performance impact. It canbe determined that there can exist an approximately a 3.2% per 10 aF/μmof Cof increase (assuming that N-type FETS (NFETs) and P-type FETs(PFETs) track together in Cof).

The exemplary embodiments of this invention overcome this problem byproviding a silicon sidewall spacer, in combination with a MHK gate, toreduce Cof and thus also reduce Cmiller.

The use of exemplary embodiments of this invention creates a structurewith a thin-polysilicon or amorphous silicon sidewall that gates the FETextension region. Since the gate sidewall is made to be silicon, thesidewall depletion that occurs beneficially lowers the Cof to similarlevels as in poly-silicon gated FETs. Additionally, since primarily onlythe extension regions are gated with silicon (and therefore a relaxedEOT is present), the scaled EOT in the MHK transistor channel ismaintained.

In general, the overall fabrication scheme described below may bestandard until the gate stack etch. As in a normal process flow themetal etch stops on the hi-k material (such as on a layer of HfO₂). Atthis step, in accordance with the exemplary embodiments of thisinvention, deposition occurs of polysilicon (either CVD or PECVD) in thethickness range of about 10-20 nm. Then, using RIE, a thin poly-siliconsidewall gate is formed that is disposed largely over the deviceextension region. Then, processing may continue as in a conventional MHKprocess flow, such as by removing the hi-k material and growing MLDnitride and subsequent diffusion spacers.

FIGS. 1A through 1G are each an enlarged cross-sectional view of asemiconductor-based structure and depict metal gate process flow inaccordance with the exemplary embodiments of this invention. In theseFigures an NFET and a PFET are shown arranged in a side-by-side mannerfor convenience of description, and not as a limitation upon thepractice of the exemplary embodiments of this invention.

FIG. 1A shows a Si substrate 10 having an overlying oxide layer 12(e.g., 3 μm) and overlying Si and STI regions 14A, 14B. A conventionalHfO₂/TiN deposition may provide gate stack layers 16 and 18,respectively. The HfO₂ layer 16 may be considered as the high-k layer(e.g., k in a range of about 20-25, as compared to 3.9 for SiO₂) and mayhave a thickness in a range of about 1-3 nm. The TiN layer 18 may beconsidered as the metal (or metal-like layer) and may have a thicknessof about 10 nm. Layers 16 and 18 together form the (as yet unpatterned)MHK gate stack. This initial structure may represent a standard SOI (orwithout BOX bulk) CMOS with a MHK gate stack.

Note that the exemplary embodiments of this invention are not limitedfor use with HfO₂ as the high-k material, and other metal oxide-basedmaterials may be used as well, such as a uniform or a composite layercomprised of one or more of Ta₂O₅, TiO₂, Al₂0₃, Y₂O₃ and La₂O₅.Materials other than TiN that may be used for the metal-containing layer18 include, but need not be limited to, one or more of Ta, TaN, TaCN,TaSiN, TaSi, AlN, W and Mo.

FIG. 1B shows the deposition of an amorphous Si or a poly Si layer 20,which may have a thickness in a range of about 30-100 nm, and subsequentdeposition and patterning of PR to form PR regions 22. Each PR region 22is located where a device gate is desired to be formed.

FIG. 1C, depicted without the underlying Si substrate 10 and oxide layer12 for simplicity, shows the result of a gate stack etch (which alsoremoves the PR regions 22). In accordance with an aspect of thisinvention, the gate stack etch stops at the high-k layer 16 of HfO₂.

FIG. 1D shows a blanket deposition by, for example, CVD or PECVD of alayer 24 of amorphous Si or polycrystalline (poly) Si. The Si layer 24may have a thickness in a range of about 10-20 nm. FIG. 1D also shows,further in accordance with the exemplary embodiments, the selectiveetching of the Si layer 24 so that it remains as a thin layer only onthe gate sidewalls, and has a thickness in a range of about 3-6 nm.Again, the etching stops on the high-k layer 16. Over the metal portions(the TiN portions 18) of the underlying gate structure the Si sidewalllayer 24 is depleted, which is a desired outcome.

FIG. 1E shows the etching and removal of the high-k HfO₂ layer 16,except for that portion within each gate stack and underlying the TiN18. Note that as a result of the removal of the high-k HfO₂ layer 16 alateral extent of the remaining portion of the layer 16 of highdielectric constant material is greater than a lateral extent of theoverlying layer 18 of metal. The remaining portion of the high-k HfO₂layer 16 may be seen to resemble a pedestal-like structure that supportsboth the overlying metal layer 18, the amorphous or polycrystalline Silayer 20, and the amorphous or polycrystalline depleted Si sidewalllayer 24.

As but one example a wet etch using a dilute hydrofluoric acid (DHF)solution may be used to remove the high-k HfO₂ layer 16, as described inan article “Etching of zirconium oxide, hafnium oxide, and hafniumsilicates in dilute hydrofluoric acid solutions”, Viral Lowalekar, SriniRaghavan, Materials Research Society, Vol. 19, #4, pgs. 1149-1156.

FIG. 1E also shows a result of depositing and etching a thin (e.g.,about 3-6 nm) nitride or oxide offset spacer 26 that covers the Si layer24 remaining on the gate sidewalls.

The remainder of the metal gate process flow may be conventional forCMOS processing, and can include providing oxide and/or nitridediffusion spacers and implants and final RTA.

For example, FIG. 1F shows a result of selectively masking alternativelythe NFET and PFET so as to implant the other to provide extensions 28and halos 30, and FIG. 1G shows the result of the deposition and etchingof a final spacer 32 (nitride or oxide deposited by PECVD), typicallyhaving a thickness of about 2-10 nm. FIG. 1G involves masking the PFETand implanting the NFET (using for example As or P), and masking theNFET and implanting the PFET (using for example B or BF₂). Subsequentannealing provides relatively deep diffusions for forming source anddrain regions separated by the gate region. Subsequent processing mayprovide, in a conventional manner, silicide gates and diffusions(typically with Ni or Co) to complete the NFET and PFET transistors.

It may be appreciated that even if one were to experience an increase inextension resistance of about 6%, when applied to the NFET and the PFETthis would translate into a resistance penalty on the order of about1.4%, which is more than compensated for by the improvement in theCmiller.

The exemplary embodiments of this invention can provide an undoped(intrinsic) Si gate sidewall 24 that doping in the main poly 20 maylater diffuse into. The exemplary embodiments of this invention can alsoprovide in-situ doped or implanted silicon (poly or amorphous) sidewalls24, and both for the NFET and the PFET.

It can be appreciated that the MHK device fabrication processesdiscussed above are compatible with CMOS semiconductor processingmethodology.

Various modifications and adaptations may become apparent to thoseskilled in the relevant arts in view of the foregoing description, whenread in conjunction with the accompanying drawings and the appendedclaims. As but some examples, the use of other similar or equivalent MHKmaterial systems may be attempted by those skilled in the art. However,all such and similar modifications of the teachings of this inventionwill still fall within the scope of this invention.

For example, it should be noted again that the exemplary embodiments ofthis invention are not limited for use with MHK gate structurescomprised only of HfO₂ and TiN. As non-limiting examples, a ZrO₂ or aHfSi_(x)O_(y) material may be used instead, as both exhibit a highdielectric constant (k of approximately 20-25) needed to provide alarger equivalent oxide thickness. In addition, the various layerthicknesses, material types, deposition techniques and the like thatwere discussed above are not be construed in a limiting sense upon thepractice of this invention.

Furthermore, some of the features of the examples of this invention maybe used to advantage without the corresponding use of other features. Assuch, the foregoing description should be considered as merelyillustrative of the principles, teachings, examples and exemplaryembodiments of this invention, and not in limitation thereof.

1.-7. (canceled)
 8. A metal high dielectric constant (MHK) transistor,comprising: a substrate; a MHK gate structure disposed on the substratebetween a source region and a drain region, the MHK gate structurecomprising a layer of high dielectric constant material and an overlyinglayer comprised of a metal, the MHK gate structure having an overlyinglayer comprised of silicon, where a lateral extent of the layer of highdielectric constant material is greater than a lateral extent of theoverlying layer of metal; a sidewall layer comprised of silicon disposedon sidewalls of the MHK gate structure to cover the layer comprised ofmetal and the overlying layer comprised of silicon, said sidewall layeralso being disposed over a top surface of the underlying layer of highdielectric constant material; and an offset spacer layer disposed overthe layer comprised of silicon and over exposed portions of the layer ofhigh dielectric constant material.
 9. The MHK transistor of claim 8,where the layer of high dielectric constant material is comprised of atleast one of HfO₂, Ta₂O₅, TiO₂, Al₂0₃, Y₂O₃ and La₂O₅.
 10. The MHKtransistor of claim 8, where the layer comprised of metal is comprisedof at least one of TiN, Ta, TaN, TaCN, TaSiN, TaSi, AlN, W and Mo. 11.The MHK transistor of claim 8, where the sidewall layer is a depletedlayer comprised of amorphous silicon.
 12. The MHK transistor of claim 8,where the sidewall layer is a depleted layer comprised ofpolycrystalline silicon.
 13. The MHK transistor of claim 8, where themetal high dielectric constant (MHK) transistor is a P-type FET.
 14. TheMHK transistor of claim 8, where the metal high dielectric constant(MHK) transistor is an N-type FET. 15.-20. (canceled)